Solver Find highest machining parameters by cutter radius and material

Source code of 'Find highest machining parameters by cutter radius and material'

This Solver (Find highest machining parameters by cutter radius and material) was created by by ichudov(507)

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==section input
This solver finds recommended RPM and feedrates. Recommended feedrates are taken from 
<A HREF=http://www.endmill.com/pages/training/spdfeed.html>http://www.endmill.com/pages/training/spdfeed.html</A>. Horsepower calculations are from <A HREF=http://www.mmsonline.com/articles/start-with-the-right-speeds-and-feeds>http://www.mmsonline.com/articles/start-with-the-right-speeds-and-feeds</A>.

Material: *[choice material Aluminum Brass MildSteel Plastic]
Cutter: *[choice cutter Carbide HSS], Diameter: *[input diameter=0.25] inches, *[input flutes=4] Flutes.

Depth of cut: *[input depth=0.25]
Maximum mill RPM: *[input max_rpm=2400]
Maximum mill HP: *[input max_hp=2]

==section solution
perl

# See http://www.endmill.com/pages/training/spdfeed.html
# http://www.mmsonline.com/articles/start-with-the-right-speeds-and-feeds

my $pi = 3.141592653589793;

my $sfmTable = 
{
  Carbide => 
  {
    Aluminum => "600-1200",
    Brass    => "200-350",
    MildSteel=> "100-350",
    Plastic  => "600-1200",
  },
  HSS => 
  {
    Aluminum => "200-600",
    Brass    => "100-200",
    MildSteel=> "80-100",
    Plastic  => "200-600",
  }
};

my $chipLoadTablePerInchOfCutter = 
{
  Carbide => 
  {
    Aluminum => 0.008,
    Brass    => 0.005,
    MildSteel    => 0.006,
    Plastic  => 0.010,  
  },
  HSS => 
  {
    Aluminum => 0.002,
    Brass    => 0.002,
    MildSteel    => 0.002,
    Plastic  => 0.002,  
  }
};

my $horsepowerPerMaterial = {
  Aluminum => 0.25,
  Brass => 0.5,
  MildSteel => 1.25,
  Plastic => 0.25,
};

my $sfm_range = $sfmTable->{$cutter}->{$material};
$sfm_range =~ /(\d+)-(\d+)/ || return 0;
$sfm_min = $1;
$sfm_max = $2;

print "SFM Range $sfm_range, diameter=$diameter.\n\n";

$rpm_min = int( $sfm_min*12/$pi/$diameter );
$rpm_max = int( $sfm_max*12/$pi/$diameter );

print "Recommended RPM: $rpm_min to $rpm_max RPM.\n\n";

my $adjusted = undef;

if( $rpm_min > $max_rpm ) {
  print "Minimum RPM exceeds mill maximum of $max_rpm, adjusted to $max_rpm.\n\n";
  $rpm_min = $max_rpm;
  $adjusted = 1;
}

if( $rpm_max > $max_rpm ) {
  print "Maximum RPM exceeds mill maximum of $max_rpm, adjusted to $max_rpm.\n\n";
  $rpm_max = $max_rpm;
  $adjusted = 1;
}

if( $adjusted ) {
 print "NEW (adjusted for max speed) Recommended RPM: $rpm_min to $rpm_max RPM.\n\n";
}

my $chipload = $chipLoadTablePerInchOfCutter->{$cutter}->{$material}*$diameter;
print "Chip load per tooth: $chipload inches.\n\n";

$feedrate_min = sprintf( "%.2f", $chipload*$flutes*$rpm_min );
$feedrate_max = sprintf( "%.2f", $chipload*$flutes*$rpm_max );

print "Feedrate: $feedrate_min to $feedrate_max IPM (Inches per Minute)\n\n";

my $removal_min = $depth * $diameter * $feedrate_min;
my $removal_max = $depth * $diameter * $feedrate_max;

print "Material Removal Rate: $removal_min to $removal_max cubic inches per minute.\n\n";

my $hp_min = $horsepowerPerMaterial->{$material}*$removal_min;
my $hp_max = $horsepowerPerMaterial->{$material}*$removal_max;

print "Required horsepower: $hp_min to $hp_max\n\n";

if( $hp_max > $max_hp ) {
  $feedrate_max *= $max_hp/$hp_max;
  $hp_max = $max_hp;
  print "Horsepower at max feedrate exceeds limit of $max_hp. Max feedrate adjusted to: $feedrate_max.\n\n";
  $adjusted = 1;
}

if( $hp_min > $max_hp ) {
  $feedrate_min *= $max_hp/$hp_min;
  $hp_min = $max_hp;
  print "Horsepower at min feedrate exceeds limit of $max_hp. Min feedrate adjusted to: $feedrate_min.\n\n";
  $adjusted = 1;
}

print "
Final Result: 
<TABLE BORDER=1>
 <TR><TD>Parameter</TD><TD>Minimum</TD><TD>Maximum</TD></TR>
 <TR><TD>RPM</TD> <TD>$rpm_min</TD><TD>$rpm_max</TD></TR>
 <TR><TD>Feed rate</TD> <TD>$feedrate_min</TD> <TD>$feedrate_max</TD> <TR> 
 <TR><TD>Horsepower</TD> <TD>$hp_min</TD> <TD>$hp_max</TD> <TR> 
</TABLE>";

==section output
rpm_min, rpm_max, feedrate_min, feedrate_max

==section check
 material=Aluminum cutter=Carbide diameter=0.25 flutes=4 depth=0.25 max_rpm=24000 max_hp=2 rpm_min=9167, rpm_max=18334, feedrate_min=73.34, feedrate_max=146.67